Method for separation of constituents from matrices

ABSTRACT

The present invention provides an apparatus useful for the separation of hazardous and non-hazardous organic and inorganic constituents from various matrices. A method of separating such constituents is also provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.11/806,994, filed Jun. 5, 2007, which is a continuation of U.S.application Ser. No. 09/191,702, filed on Nov. 13, 1998 which is nowU.S. Pat. No. 7,244,401. Each of these applications, in their entirety,are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Since the early 1950's, the various branches of the United StatesDepartment of Defense (DOD) and the United States Department of Energy(DOE) have been aggressively developing and manufacturing nuclearweapons and energy components involving various radioactive materials.The process of refining nuclear materials and decontaminating variousapparatus used in these processes and others with various types oforganic and inorganic materials has generated hundreds of thousands oftons of soils, sludges, debris or other residuals contaminated withradionuclides and various hazardous and non-hazardous organic andinorganic chemical constituents. The United States EnvironmentalProtection Agency (EPA) has defined a waste that contains radionuclidesand hazardous or non-hazardous waste constituents as a mixed waste.

Historically, mixed waste was typically stored on site in containers indesigned containment areas, or storage vessels or disposed of inlandfill cells or trenches. The disposal of mixed waste in DOD or DOElandfills or trenches is no longer permitted. Due to the promulgation ofEPA regulations, mixed waste is not permitted to be disposed of at anEPA approved hazardous waste facility or a radioactive waste facilityuntil the constituents can be separated and segregated from each other.

This need to remediate the mixed waste at these sites is beingaccelerated due to the fact that the DOE and DOD are currentlyundergoing a major restructuring effort, whereas numerous DOE and DODfacilities throughout the country are being decommissioned anddecontaminated for light industrial, commercial or residentialredevelopment. A large percentage of these facilities contain soil,sludges or other residuals, which is defined by the EPA as a mixedwaste. To compound the problem, the mixed waste that has been buried intrenches and landfills has had a significant impact on groundwaterreserves in some locations. These areas must be remediated in accordancewith EPA regulations which involves in most cases the removal andremediation of the pollution source materials (non-liquid matrices).

The present invention discloses a method that is capable of separatinghazardous and non-hazardous organic and inorganic constituents from thenon-liquid matrices without destabilizing or spreading theradionuclides. After separation, the radioactive waste stream is eitherdisposed of at the DOE or DOD facility in accordance with EPAregulations, or disposed of at an EPA approved radioactive wastefacility. This allows for a significant economic benefit to handle thiswaste stream in this manner. Currently, there are virtually no availablemethods to conduct the separation of this waste stream in anenvironmentally sound and cost effective manner.

In addition to mixed waste, the annual generation of hazardous andnon-hazardous (chemically contaminated) wastes in the United Statesalone is estimated to be in the range of hundreds of millions of metrictons. Industries throughout the world rely on processes in manufacturingwhich generate waste products routinely. Many of these waste productsare disposed of as hazardous waste, which is very expensive. There is aneed to reclaim for reuse some of the raw materials by separating thecontaminants from various matrices. This allows industry to minimize thewaste that is produced, lower operating costs and comply with currentregulations.

The hazards to public health and the environment, which are posed bythese various chemical constituents, are well known and documented.Various methods for the destruction or decomposition of high boilingpoint hazardous wastes is extremely expensive. It is not very costeffective to utilize high grade energy to thermally destroy an entirehazardous waste matrices when the contaminant itself is such a smallportion of the volume by weight. Also, because the non-liquid matrixwhich has become contaminated due to contact with the chemical compoundshould be reused or recycled if possible. It is more cost effective withregard to matrices contaminated with hazardous wastes such as PCBs,pesticides, herbicides, PCPs, dioxins, furans, and the like to minimizethe waste stream which require expensive destruction or decompositionmethods by separating the bulky non-liquid matrix which typically makesup between 75% to 90% of the waste stream volume.

Therefore, the invention provides an economical waste minimization andresource recycling method as an alternative option to the current art inresponse to a market need for technology to better handle industrialprocess waste, mixed waste and hazardous waste streams in anenvironmentally sound and cost effective manner. O'Ham (U.S. Pat. No.5,127,343, the entire contents of which are herein incorporated byreference) teaches an apparatus and method for decontaminating andsanitizing soil, particularly soil containing petroleum hydrocarbons,such as gasolines, oils, and the like in a batch process where the soilis stationary during treatment. This process was specifically designedin response to the large market need for on-site treatment technology ofpetroleum hydrocarbon contaminated soils from gasoline service stationsand other related users of petroleum products, in response to theregulatory requirements of the Underground Storage of HazardousSubstances Act and related regulations, which required petroleumhydrocarbon contaminated soils to be remediated.

The prior art has no means of controlling fugitive dust during theloading and unloading of matrices. Soil is normally transported vialoader from a stockpile to the processing device. In doing so thecontaminants are spread through spillage and wind born dust. Bothworkers and possible bystanders, or nearby public have a much higherpotential exposure to contaminants as well as possible uncontrolledreleases of contaminants to the environment The prior art requires 20%and greater downtime to perform maintenance of the processor. Soils areplaced directly into a process unit on screens (vacuum tubes) surroundedby a filter media (pea stone). Screens become easily plugged requiringconstant cleaning between batches. The entrance door is lowered to allowfor a front end loader to enter the chamber and deposit the soils fortreatment and raised to create a track for the carriage of heaters toroll on top of the chamber for treatment. The entrance door hingesbecome blocked with matrices and filter media and have to be cleanedafter each batch. These doors become easily damaged from this processand become nearly impossible to seal with air by passing the soil,resulting in insufficient treatment. Furthermore, damage to the hingeresults in the access door becoming out of line. When this happens, thetrack for the heater carriage becomes out of line and can cause theheater carriage to fall off of the track on this side of the unitresulting in increased downtime.

Prior art was unreliable in treatment. Air flows through the static bedare uneven and variable resulting in temperature gradients across thematrix to be treated. Air bypasses were caused by plugged screens andpea stone, and the inability to seal the loading door. Also, the vacuumscreens were located directly under only approximately 50% of the staticsoil bed surface area, resulting in incomplete treatment throughout thesoil or creating “cold spots”. Uneven heating results in inadequatetreatment.

The prior art uses expensive filter media which adds to the wastestockpile and cost to operate.

The prior art requires extensive cleaning between jobs. Oftendecontamination procedures are unsuccessful. This is due to the matrixplacement directly within the treatment chamber. The matrices are forcedinto hard to access areas of the apparatus.

The prior art entrains dust particles and deposits them into theemission control system, restricting air flows and causing excessivemaintenance requirements.

Prior art only allows for the treatment of hydrocarbons.

Prior art is only applicable to removal of hydrocarbons through thermalprocesses. The review of the prior art indicates that the art is limitedto the removal of hydrocarbons from soils and is not suitable, withregards to economical, ecological and safety matters, for the treatmentof various volatile organic and inorganic chemicals and high boilingpoint chemicals. Therefore, a need exists for an economical andenvironmentally friendly method that separates volatile organic andinorganic contaminants from non-liquid matrices and collects thesecontaminants for recycling or reuse. A need also exists for a systemwhich allows for the reuse of the decontaminated non-liquid matrices.This method provides a social benefit by providing an ecologically soundsolution for the minimization of waste streams in an economical manner.

SUMMARY OF INVENTION

The present invention provides an apparatus for the separation of wasteconstituents from matrices, comprising: a vessel having a bottom and atop; where the top has a manifold for removal of gases; and a means forheating interior of said vessel, preferably located in the bottom ofsaid apparatus. Preferably, the apparatus further comprises a removabletray, preferably between 1 and 4 trays. The apparatus may be permanentlymounted or, is preferably mobile. In a preferred embodiment, theapparatus further comprises a means for generating a vacuum forwithdrawing gases through the manifold, preferably ranging from 0″mercury to about 29″ mercury.

In a preferred embodiment, the vessel is rectangular in shape andcomprises from one to four sides, with the sides of the tray or trayseffectively forming the sides of the vessel upon insertion into thebottom or base of the vessel. According to a preferred embodiment, thevessel lacks any sides. The tray preferably comprises a bottom havingorifices, such that the bottom of the tray is capable of supportingmatrices and yet allows air to pass upwardly through orifices andmatrices. The bottom may be, for example, a screen or may be slotted.The apparatus can vary in its dimensions, depending upon such factors asthe amount of matrices to be treated, the location of the treatmentsite, or whether the unit is designed to be fixed at a site or mobile,in one embodiment, the tray is of size, dimension and capacity so thatit can be moved and loaded into vessel with a fork truck. Typically, forlarger scale operations, the tray is designed to be loaded with matricesfrom the top and has a loading capacity of at least about 2.5 cubicyards. The tray may also comprise a hinged gate at an opposite end ofthe fork lift pockets for unloading treated matrix. In anotherembodiment, the apparatus is adapted for small scale usage, where thetray has a capacity of, for example, about 1 cubic foot.

According to one embodiment, the apparatus further comprises a means formechanically agitating the matrices. The apparatus may further comprisea means for the introduction of chemical treatment additives.

In a further embodiment, the bottom surface of the top or the manifoldcomprises a high temperature silicon or other heat resistant gasket toseal the tray to the top or manifold so that air is directed throughtrays and matrices contained in the tray, and not around the tray.According to one embodiment, the top can be moved vertically. In anotherembodiment, the manifold optionally contains a 1 to 100 micron dryfilter media which physically separates the matrix particles entrainedin the purge gas air stream.

The apparatus may also further comprise a means for remotely monitoringoperation of said apparatus using a controller system and transducers toconvey information to a computer. The present invention further providesa method for the separation of hazardous and non-hazardous organic andinorganic waste constituents from matrices comprising: placing matricesin a container; heating matrices; creating a subatmospheric pressurewithin the matrices by establishing a vacuum above the matrices; andremoving the gaseous constituents from the matrices. The matrices areselected from radioactive materials, industrial process waste streams,soils, sludges, activated carbon, catalysts, aggregates, biomass,debris, sorbents, drilling mud, drill cuttings and the like. The boilingpoints of the constituents can range, for example, from about 30 degreesFahrenheit to about 1600 degrees Fahrenheit. Examples of constituentswhich may be removed include ammonia, mercury, mercuric compounds,cyanide, cyanide compounds, arsenic, arsenic compounds, selenium,selenium compounds, and other metals and their salts.

According to one embodiment, the constituents are not thermallydestroyed or combusted during separation of constituents from thematrices. The method may comprise reversibly phase changing theconstituents separated from the matrix by condensation of or physicalfiltration or adsorption of constituents. In one embodiment, theconstituents are retained in the matrices for less than 0.5 secondsafter desorption temperature of constituents has been achieved.

The method may comprise heating the matrices in an indirect manner byexposure to light energy with an emission spectrum between 0.2 and 14microns. In one embodiment, the surface of matrices exposed to infraredenergy becomes a secondary emitter and purge air convectively transfersheat to the matrix surface of the loaded tray. In another embodiment,the surface of the matrices exposed to light energy becomes an emitterand transfers heat conductively to matrix layers above the surfacesexposed to light energy. The method may further involve heating of thematrices by convective means whereby heat is conducted to the matrixlayers above the bottom surface of the matrix.

In one particular embodiment, organic chemicals are separated from thematrices containing radionuclides and inorganic metallic constituents.The constituents may be recovered and refined for recycling purposes.The method may further comprise a means for purging gas vapors andconstituents to be condensed and collected. In a further embodiment, thedischarge air stream is recirculated below the trays to form asubstantially closed loop system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the apparatus of the invention.

FIG. 2 shows top, bottom and side views of an agitator tray.

FIG. 3 shows several views of a static or removable tray used inpracticing the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a method for the separation ofhazardous and non-hazardous organic and inorganic constituents fromvarious matrices. More particularly, the invention relates to a methodfor the separation of these various constituents from matrices by usingone or more of the following principles: low temperature thermaldesorption, radiant energy, convective heating, conductive heating, airstripping, vacuum distillation, reduced pressure volatilization andchemical volatilization through the addition of chemical additives andthe like. More specifically, the invention relates to a method for theremediation of various matrices whereas a primary result of the processis to provide a waste minimization and resource recycling benefit.Preferably, the invention relates to a method for the remediation of thefollowing waste stream areas: (1) separation of hazardous andnon-hazardous organic and inorganic chemical constituents fromradionuclide contaminated matrices without spreading or destabilizingthe radionuclide contamine separation of raw materials and hazardous andnon-hazardous organic and inorganic chemical constituents from anindustrial process waste stream; and (2) the separation of hazardous andnon-hazardous organic and inorganic chemical constituents from variousmatrices, including but not limited to, sludges, soils, activatedcarbon, catalysts, aggregates, biomass, debris and the like.

The Matrix Constituent Separator provides a controlled air flowdistribution which the prior art lacked. The Matrix ConstituentSeparator enables an even distribution of air flow and heat drawnthrough the matrices contained in either the static or agitator tray toensure complete desorption of the constituents contained within theentire matrix volume. For the desorption of volatile and semi-volatileorganic and volatile inorganic chemicals, the lack of moving parts inthe treatment chamber affords low maintenance and thus providesincreased production and associated economical benefits.

This process enables the complete desorption, separation and collection,if desired, of all hazardous and non-hazardous organic and inorganicchemical constituents from a radioactive contaminated matrix withoutspreading or destabilizing the entrained radionuclides.

The Matrix Constituent Separator provides efficient, cost-effectiveseparation for recovery of hazardous and non-hazardous organic andinorganic chemical constituents and matrices for recycling, reuse,economic disposal or further treatment of the hazardous constituents,due to the significant volume reduction in the quantity of wasterequiring further handling.

The design of the present treatment apparatus maximizes the economicbenefits and utilization of the fuels used in the system to generateradiant energy. The process is also efficient since it does not use anyauxiliary fuels for the desorption of the chemicals from the matricesduring the treatment process, or to condense and collect the vaporizedconstituents following desorption from the matrices.

The overall process achieves a significant and desirable volume and massreduction in the waste stream which can then be recycled, reused at aneconomical benefit, disposed or further treated at significantly lowercosts. The volume of chemical contaminants that are either emitted tothe atmosphere or landfilled, are reduced substantially by the method ofthe invention because it affords a means for separating, remediating,collecting, purifying and recovering commercial products fromcontaminated matrices including the matrices themselves.

Prior art method involves heating material from the top and forces airdownwardly through the material. This action contradicts the laws ofphysics and retards the treatment process. In the prior art, convectiveheat is not captured from the burners as air is drawn downwardly throughthe system. Most of the convective heat can be observed rising off andaway from the top of the process. The MCS heats the soil from the bottomand the heater exhaust and heated air exit the system through thematrix. This process is efficient, and since heat rises naturally itdoes not require opposing forces to drive the air through the matrix.The upward air movement does not compress or compact the matrix allowingfor free air flow through the matrix. The prior art caused matrixcompaction which retards both the air flow through the system and thetreatment effectiveness.

The MCS is preferably portable, as the cost for transporting the unit tothe site to be treated is much less than the cost of moving the matricesto the treatment location and back to the place where the matrices wereto be used as backfill materials or for other reuse or disposal.

The method preferably consists of charging the matrices into bottomscreened trays which are mechanically placed into a heating frame havinga reflective bottom and three vertical sides and open to the atmosphereat the top, establishing a vacuum, or at least a partial vacuum, throughthe top of the container to establish an up draft through the generallyloosely packed matrices, heating the matrices from the bottom andpulling the hot gases upwardly behind or commingled with the gases,releasing the contaminants vapors from the matrices and removing themfrom the trays and manifold frame and collecting the contaminants vaporsin an air emission control system if desired. Finally, the trayscontaining the treated matrices are removed from the heating frame andallowed to cool in a controlled manner while another set of trays aretreated. Once the treated matrices contained within the trays havecooled, they are rehydrated within the trays in a controlled manner. Thematrices are then removed from the trays so that fugitive emission ordust are minimized.

Air is pulled through the open base of the system to a point furthestaway from the heat source. This air flow performs two functions: (1)drawing the convection heat through the source to heat the non-liquidmatrices not exposed to the light energy; and (2) reducing the vaporpressure within the treatment chamber. Second, lowering of the pressuredecreases the boiling point of the contaminants being liberated from thetreated matrices. The vapor pressure/boiling point relationship isexpressed by the following well known empirical equation for specificsubstances for which a and b values are known, wherein p=pressure in mmmercury; T=temperature in degrees Kelvin; a and b are constants given(among other places) in the CRC Handbook of Chemist and Physics, 69^(th)edition. (1988) beginning at page D-212.Log 10p=0.05223a divided by T plus b

This allows the removal of contaminants with higher boiling points atlower temperatures. The energy needed to heat the system is only aboutone-fourth as much as required by other thermal treatment systems. Thevacuum also works in a physical way as well. By physically drawing andsaturating the treated matrices with air, the heated air will displacethe other gases present and sweep them out of the treating trays whichadds to the effectiveness of the system.

In the present invention various waste matrices are placed into traysand loaded onto the heater base, a fan draws air through the systemacting on the matrices throughout the screened tray bottom. The heatersare activated, heating the matrices evenly and thoroughly to a depthbetween the range of less than an inch to over three feet. Typically,the matrices are heated to a depth in the range between 4 inches and 18inches. The effective depth of heating can be readily determined by oneskilled in the art and will be affected by such factors as heatingsource, physical characteristics of the matrix and the like. Ambient airentering the process at all locations below the matrices is also heatedand pulled upward through the matrices carrying heat to the upper layermatrices. The combination of heat and reduced pressure removes thecontaminants from the matrices and the air flow draws the removedcontaminants out of the treatment process through an emission control orcollection system. The matrices can be agitated and treatment can benon-thermal in nature if desired.

The system is a batch treatment process used to separate hazardous andnon-hazardous organic and inorganic chemical constituents from varioussolid and semi-solid matrices. These matrices include but are notlimited to radioactive contaminated matrices, industrial process wastestreams, sludges, soils, activated carbon, catalysts, aggregates,biomass, debris and the like. The chemical constituents are separatedfrom the matrices by heating the matrix in a tray while purging copiousvolumes of air or other gases through the matrix. The purge gas streamflows through a series of non-destructive emissions control componentswhich remove the chemical constituents from the air stream by physicalseparation, condensation and absorption. In the preferred embodiment,the present invention comprises but is not limited to the followingcomponents:

Dry Particulate Filter

Condensing System

HEPA Filters

Carbon Absorption

Liquid Scrubbers

Reverse Osmosis

Chemical Precipitation

Physical Phase Separation

Coalescing Filters

The apparatus of the present invention can be described by reference tothe following figures:

FIG. 2:

-   -   1. Shaft support beam which houses the bearing and shaft that is        connected to the matrix mixing flights.    -   2. Slotted screened bottom of tray which contains the        contaminated matrices during processing.    -   3. Mixing flight which moves through matrix contained in tray to        facilitate mixing of matrices during processing.    -   4. Hydraulic motor which drives mixing flights.    -   5. Slave sprocket which reduces power requirements and drives        flights.    -   6. Drive chain which connects slave sprocket to drive sprocket.    -   7. Drive sprocket which is coupled to hydraulic motor for        driving mixing flights.    -   8. Protective housing to keep hydraulic motor from hostile        environments.    -   9. Hydraulic motor which drives mixing flights    -   10. Drive sprocket which is coupled to hydraulic motor for        driving mixing flights.    -   11. Drive chain which connects slave sprocket to drive sprocket.    -   12. Slave sprocket which reduces power requirements and drives        flights.    -   13. Slotted screened bottom of tray which contains the        contaminated matrices during processing.    -   14. Agitator tray used to process matrices prior to, during and        after introduction of chemical additives to enable treatment of        certain inorganic contaminants.    -   15. Mixing flight which moves through matrix contained in tray        to facilitate mixing of matrices during processing.    -   16. High temperature support bearing which allows slave shaft to        rotate.    -   17. Central drive shaft in which flights are attached.        FIG. 3:    -   18. Slotted screened bottom of tray which contains the        contaminated matrices during processing.    -   19. Hinge to dump gate for matrix removal following treatment.    -   20. Dump gate door which swings open to dump matrices.    -   21. Dump gate latch which prevents gate from opening during        treatment.    -   22. pick-up pocket enables the forklift to move, load, unload        and dump trays.    -   23. Dump gate latch which prevents gate from opening during        treatment.    -   24. Hinge to dump gate for matrix removal following treatment.    -   25. Forklift pick-up pocket enables the forklift to move, load,        unload and dump trays.    -   26. Slotted screened bottom of tray which contains the        contaminated matrices during processing.    -   27. Bottom screen support to support weight of matrix loaded        into trays.    -   28. Forklift pick-up pocket enables the forklift to move, load,        unload and dump trays.    -   28 a. Forklift pick-up pocket enables the forklift to move,        load, unload and dump trays.        FIG. 1:    -   29. Process Burner    -   30. Radiant tube emitter    -   31. Combustion Exhaust Vents    -   32. Heater Base Assembly    -   33. High temperature silicone gasket material which seals        exhaust manifold to tray top edge.    -   34. 1 to 100 micron filter media and support frame which acts as        a physical barrier to stop particulates from exiting the system        in the air stream.    -   35. Air extraction manifold    -   36. Hydraulic cylinder for lifting exhaust manifold.    -   37. Exhaust gas outlet.    -   38. Soil treatment tray.

The chemicals can be recovered for re-refining, further treatment,disposal or recycling from these various components without destroyingthe chemical constituents. The resulting discharge air stream is eitherfree of or contains minimal concentrations of chemical constituents.This process can be used-to separate chemical constituents fromradioactive contaminated solids without commingling the radionuclideswith the chemical constituents.

In the preferred embodiment, the present invention comprises a basecontaining a multiplicity of heaters, preferably infrared heaters, whichare positioned under the matrices and placed within a portable heaterframe, with the heaters directed upwardly against the lower surfaces ofthe matrices. The apparatus also provides that the base of heaters canbe mounted permanently to the manifold frame for most applications. Anextraction blower or vacuum pump provides the impetus for upwardmovement of the contaminants through the matrix, which exits through theextraction blower or vacuum pump, or can be collected in an air emissioncontrol system if desired. Attached to the base by two hydrauliccylinders is the vacuum or exhaust manifold. The bottom surface of themanifold is gasketed with a temperature resistant gasket material. Themanifold is raised hydraulically to allow for the loading and unloadingof the screened bottom matrix trays onto the heater base. Once loaded,the upper manifold is lowered and sealed to the trays' top edge. Thisallows for the air to be drawn upwardly through the matrix and tray andnot around it.

The preferred apparatus consists of five major components: manifold;process trays; heater base; purge air fan; and emission controls system.In the preferred embodiment, the trays are typically sized toapproximately 8′×8′×17″ and contain a slotted flat stainless steelscreen. The waste matrix is loaded into the screened tray and the trayis placed on the heater base.

The heater base consists of typically 1 to 4 or more tray receptaclesand has a rack of heaters mounted in it with enough space between theheater base and the manifold to insert the tray. The tray can be raisedand lowered to aid in the tray loading and removal process. Once thetray is loaded and the manifold is lowered, the extraction fans forcepurge air through the matrix while the heaters illuminate the soils.

The surface of the matrix is heated and the purge gas stream movesthrough the matrix convectively transferring heat from the matrixsurface layer which is exposed to the light energy and to the matrixmaterials located deeper in the tray. Conductive heat transfer occurs inthe tray where matrix particles touch those particles exposed to thelight energy as well as those particles which have been heatedconvectively. The purge air stream creates an equilibrium shift in whicha vapor state is enhanced. Chemicals in the matrices exist as solids,liquids and vapors in an equilibrium state. Heat shifts the balance andgenerates more vapor. As this vapor is displaced and conveyed out of thesystem by the purge air vapor generation, it is further enhanced as thesystem tries to settle into an equilibrium state.

The Matrix Constituent Separator allows for the loading of trays at thestockpile area, and the trays, which fully contain both matrix andcontaminants, can be transported in a controlled manner to theprocessing unit without spreading contaminants or releasing fugitiveemissions. This new process also eliminates the need for workers toenter the process unit and clean out matrices, spent pea gravel filtermedia and the vacuum tubes. This significantly minimizes health andsafety concerns with regard to exposure to contaminant vapors, heatstress, burns and back problems from working in an extremely hotenvironment with heavy materials.

The MCS process allows screened bottomed trays to be loaded onto a frameeliminating the screen plugging, entrained door filter media problemsand the associated maintenance downtime. The MCS process consists ofvirtually no downtime for this reason. Should some maintenance berequired to the screen on a particular tray, this can be accomplishedwhile other trays are undergoing treatment. With the previous art,maintenance on the processor results in loss of production. The surfacearea of the static bed in the MCS processor is placed entirely on ascreen resulting in 100% coverage.

The MCS process eliminates the loading door and promotes even air flowsthrough the matrix and uniform treatment. The need for expensive filtermedia has been eliminated, lowering process cost and minimizing residualwaste for disposal. In the MCS, all of these problems have beeneliminated because the matrices are not in contact with processequipment.

In the MCS process, a 5 to 100 micron physical barrier prevents theentraining and migration of contaminants and particulates into emissioncontrol components. This makes for easy and efficient decontamination.

The MCS process can be equipped with mechanical agitators so thatmatrices can be chemically treated by mixing and through the addition ofchemical compounds used to volatilize or gasify contaminants which arewithdrawn from the trays and collected in the emission control system.

The MCS process allows for the controlled rehydration of the treatedwaste to control dust and prepare the matrix for reuse. This is notpractical in the prior art. Production is not affected as rehydration ofthe trays can occur while other trays are undergoing treatment. With theprior art, rehydration would have to occur in the treatment chamber sothat additional production is not possible. Also rehydration in thechamber results in an accumulation of water in the chamber which willimpact (increase) the treatment time of the next batch, effectingproduction.

The MCS process is configured so that it is practical to monitor matrixtemperatures, air flows, pressures and process emission controlcomponents using transducers and thermocouples. This allows operators tocontrol the treatment process accurately. Prior art lacks these controlsand could not be practically used in the matrix containment vessel. Theuse of the process controls will also limit the number of workersrequired to operate the system, thereby limiting potential exposure tohealth and safety risks. Both of these advantages will make the systemmore cost competitive.

The MCS process is a more economical and efficient means of treatmentthan the prior art.

The method of loading and unloading the prior art processor requiressignificant downtime between batches, which directly affects theproduction efficiency and economical benefit of this art. The processdesign of the MCS method realizes substantial production efficienciesand economical benefits over the prior art, resulting in part from theimprovement in downtime between batches due to loading and unloading thetreatment chamber with matrices.

In the present system all of the constituents will be converted to vaporand pneumatically conveyed by the air stream into an emission controlsystem. Because purge air volumes are excessive, a means to physicallyseparate particulates which have been entrained into the purge gasstream can be used. A dry particulate filter with pore spaces typicallyranging from 1 to 100 microns is incorporated into the manifold justabove the tray gaskets. This physical barrier stops these particles andseparates them from the constituent vapors. The vapors travel through acondenser where they are condensed to a liquid. From this stage in theprocess, the vapors and purge gas air pass through a HEPA filtertypically designed to screen out particles to 0.1 microns. The purge airtravels through carbon to further purify it. The air is finallydischarged to the atmosphere or reintroduced into the process as purgeair. Scrubbers, staged condensation and the like can also be used toachieve the purge gas vapor removal.

The matrices in the trays can be mechanically agitated and chemicaladditives introduced to the matrix to enhance the process or convertconstituents into a more volatile form for separation. This is achievedusing a flighted paddle which turns inside the tray mixing the matrices.It can also be accomplished utilizing a drag bar.

Typically, the extraction fan is the only moving mechanical part whichdrives the system. The system can also be modified in a particularembodiment where agitator trays are utilized for treatment of certainchemical constituents. These tray bottoms can be capped to achievevacuums ranging from about 0″ to about 29″ of mercury. This can furtherenhance the equilibrium shift. The results are that chemicalconstituents are separated from the matrices and collected in theemission control system without destroying them.

Inorganic and certain organic constituents can be separated by thesystem coupled with the use of a tray agitator and/or chemical addition.Some of these processes can be accomplished non-thermally. For example,a matrix contaminated with cyanide salts or organically bound cyanidescan be placed inside a static tray, if the matrix is homogeneous incomposition and permeability, or in an agitator tray if it is not. Theaddition of sulfuric, nitric, hydrochloric or other acids will producehydrogen cyanide gas which is withdrawn from the matrix and passedthrough a caustic scrubber to create sodium cyanide which then can becollected and recycled. The matrix can then be neutralized with causticand made suitable for possible reuse.

Mercury, arsenic, selenium and other transition elements can beliberated from a matrix by first acidifying the matrix then oxidizing itto get metals in their ground state. Addition of stannous chloride orsulfate will cause the hydride gas of the compound to form, releasingthe compounds of concern which are collected and passed through an acidscrubber. Ammonium can be removed from a matrix by raising the pH withcaustic and collecting the vapors in boric acid.

The mechanical agitator consists of a hydraulically powered processwhich may be chain driven beneath the bottom of the tray. The traysurface contains two flights that ride across the bottom of the screen.The flight rises in the center about 2 inches which plows through thematrix lifting the material and mixing it. The flights are attached to ashaft which protrudes below the tray screen. Below the bottom of thescreen the shaft has a sprocket connected to it. This shaft is typicallylocated in the center of the tray. The hydraulic motor shaft alsoextends through the screened bottom of the tray. There is a sprocketattached to this shaft as well. A C drive chain connects the twosprockets. When the motor shaft turns, the slave shaft turns pushing theflights through the matrix.

The heater base typically contains 8 to 12 radiant heaters that faceupward toward the matrix.

The prior art has a series of recessed chambers in which tubular screensare inserted and attached to a manifold at one end. The soil to betreated rests on the bottom of the chamber and on top of the screens.The recessed area and the screens become plugged quickly. This causeduneven heating of soils which resulted in poor and uneven treatment. Thesoil which plugs the screens has to be manually removed, causing processdowntime and health and safety concerns for the workers.

The present process does not employ a series of recessed chambers withscreens within in which the matrix rest during treatment. The processchamber is separate from the treatment trays. The chamber is equippedwith a frame in which a tray containing the matrix is placed. The trayhas a self cleaning screened bottom which clears itself of any pluggingthat may occur in the dumping process.

The boiling point of a liquid is the temperature at which the partialpressure of the substance is equal to its vapor pressure. There is adirect relationship between the final treatment temperature and thesystem operating pressure. As the system is operating, pressure isreduced and the treatment temperature required for removal of compoundsby volatilization is decreased. The MCS uses this principle of boilingpoint reduction by reducing the system pressure. The system pressure isreduced from about 0″ mercury to approximately 1″ to 30″ mercury. FIG. 1shows examples of this relationship for water, acetone, TCE and PCE.

Approximate Boiling Points of Compounds at Reduced Pressure Boiling pt.Compound Boiling pt. at 0″ Hg (° F.) at 25″ Hg (° F.) Water 212 72Acetone 133 44 Trichloroethylene 189 65 Tetrachloroethylene 250 86

Vacuum is expressed in terms of total vacuum in inches of mercury

Referring to FIG. 1, it is readily seen that the relationship betweenthe boiling point and the system pressure, although direct, is notlinear. This non-linearity is described by the Clausius-Clapyronequation:

$\begin{matrix}{{p = {{{p*x\mspace{14mu}\exp} - {C\mspace{14mu}{with}\mspace{14mu} C}} = {\left( {{delta}\mspace{14mu} H_{VAP}} \right) \times \left( {1 - 1} \right)}}}\mspace{304mu}{R{TT}*}} & {{Equation}\mspace{14mu} 1}\end{matrix}$where:

p* is the vapor pressure (atm.) at the temperature T* (*R);

p is the vapor pressure (atm.) at temperature T (*a);

R is the universal gas constant (BTU/mol−*R); and

delta H_(VAP) is the heat of vaporization (BTU/lb)

Three assumptions are made for the above equation to hold true: 1) thechange in the molar volume equals the molar volume of gas; 2) the gasbehaves as an ideal gas; and 3) the enthalpy of vaporization (deltaH_(VAP)) is independent of temperature. Table 1 compares the boilingpoint from tabular data to the boiling point calculated with theClausius-Clapyron equation for several chemicals at a pressure ofapproximately 25″ mercury.

Another important parameter related to air flow is air stripping. Airstripping is the process of using the carrier gas, air, to remove thecontaminants from the non-liquid materials. The rate at which acontaminant is stripped from the soil depends on its vapor pressure andstability in water. This process can be described by Henry's Law whichis represented by the following equation:P _(a) =X _(a) ×k(T)  Equation 2where

P_(a) is the partial pressure of component a

k is Henry's Law constant for component a at temperature T

X_(a) is the mole fraction of a in solution (X a is small)

Therefore, desorption of each contaminant is taking place throughout theentire process, not only when the boiling point of each of the compoundsis reached.

Chemical volatilization consists of a two step chemical reaction whichis shown below.

$\begin{matrix}\begin{matrix}{{C(l)}\mspace{14mu}{at}\mspace{14mu} T_{o}} & {Heat} & {{C(l)}\mspace{14mu}{at}\mspace{14mu} T_{bp}} \\\; & {{Delta}\mspace{14mu} H_{t}} & \;\end{matrix} & {{Equation}\mspace{14mu} 3} \\\begin{matrix}{{C(l)}\mspace{14mu}{at}\mspace{14mu} T_{bp}} & {Heat} & {{C(g)}\mspace{14mu}{at}\mspace{14mu} T_{bp}} \\\; & {{Delta}\mspace{14mu} H_{v}} & \;\end{matrix} & {{Equation}\mspace{14mu} 4}\end{matrix}$where:

C is the specific (and pure) chemical with a defined boiling point (Tbp)

C (l) is the above chemical in the liquid phase and at some temperature,T

C (g) is the above chemical in the gaseous phase and at sometemperature, T

T_(o) is ambient temperature

T_(bp) is the boiling point temperature

In the first reaction, the temperature of the contaminant (or chemical)is increased until the boiling point is reached. The amount of energyrequired to raise the temperature from the initial temperature to theboiling point depends on the heat capacity (for the liquid phase) andthe quantity of the contaminant. For example, water in the liquid phaserequires 1 BTU of energy to raise the temperature of 1 lb 1 degreesFahrenheit. The second reaction shows that after the contaminant reachesits boiling point, the temperature remains constant while the liquidvaporizes. The heat of vaporization is the amount of energy required toproduce a phase change from the liquid phase to the gaseous phase. Forwater, the heat of vaporization is 950 BTU/lb (at 212 degreesFahrenheit). The total heat required is the sum of the enthalpies of theindividual reactions or delta H, plus delta H.

There are three primary components in the matrix: 1) the contaminants;2) water; and 3) the matrix itself. The contaminants and the waterundergo the two-step chemical reaction of volatilization while thematrix is only heated. The contaminants are present in concentrations ofparts per million (ppm), the water in concentrations ranging from 10-20%and the remaining 80-90% is the matrix.

The two main drivers for the required energy input are the water and thematrix since the contaminants are present in relatively lowconcentrations. As explained above, energy is used to heat the water toits boiling point and is continually added to vaporize the water andheat the system to the final target treatment temperature. Thus, indetermining the total amount of energy required to reach a targettreatment temperature, the relative amounts of matrix and water (andtheir corresponding heat capacities) must be taken into consideration aswell as the final target treatment temperature which is dependent on thehighest boiling point contaminants.

The invention claimed is:
 1. A method for the separation of hazardousand non-hazardous organic and inorganic waste constituents from matricescomprising: placing matrices in a vessel, said vessel comprising a frameadapted to receive one or more removable trays; heating matrices with aheater, said heater being positioned in a manner to allow heat to entersaid vessel at a position below said one or more removable trays wheninserted in said frame; creating a subatmospheric pressure within thematrices by establishing a vacuum above the matrices; and removing thegaseous constituents from the matrices through a manifold positioned ontop of said vessel; wherein said one or more removable trays are adaptedto be inserted in said frame, said one or more removable trayscomprising a bottom part and peripheral sidewalls extending therefrom,said bottom part being capable of supporting the matrices and beingstructured so as to define orifices in the bottom; and wherein, uponinsertion of said one or more removable trays in said vessel, saidperipheral sidewalls of said one or more removable trays effectivelyform the sides of said vessel.
 2. The method of claim 1 herein saidmatrices are selected from radioactive materials, industrial processwaste streams, soils, sludges, activated carbon, catalyst, aggregates,biomass, debris, sorbents, drilling mud and drill cuttings.
 3. Themethod of claim 1 wherein boiling points of said constituents range fromabout 30 degrees Fahrenheit to about 1600 degrees Fahrenheit.
 4. Themethod of claim 1 wherein said constituents are selected from ammonia,mercury, mercuric compounds, cyanide, cyanide compounds, arsenic,arsenic compounds, selenium, selenium compounds, and other metals andtheir salts.
 5. The method of claim 1 further comprising the separationof constituents from matrices in which constituents are not thermallydestroyed or combusted.
 6. The method of claim 1 further comprisingreversibly phase changing constituents separated from matrix bycondensation of or physical filtration or adsorption of constituents. 7.The method of claim 1 wherein constituents are retained in matrices forless than 0.5 seconds after desorption temperature of constituents hasbeen achieved.
 8. The method of claim 1 further comprising heatingmatrices in an indirect manner by exposure to light energy with anemission spectrum between 0.2 to 14 microns.
 9. The method of claim 1wherein the surface of matrices exposed to infrared energy becomessecondary emitter and purge air convectively transfers heat to matrixsurface of loaded tray.
 10. The method of claim 1 wherein surface ofmatrices exposed to light energy becomes emitter and transfers heatconductively to matrix layers above surfaces exposed to light energy.11. The method of claim 1 wherein matrices heated by convective meansconducts heat to matrix layers above surface of matrix.
 12. The methodof claim 1 further comprising separating organic chemicals from matricescontaining radionuclides and inorganic metallic constituents.
 13. Themethod of claim 1 wherein said vacuum ranges from 0 inches mercury toabout 29 inches mercury.
 14. The method of claim 1 further comprisingmeans for recovery of constituents which can be refined for recyclingpurposes.
 15. The method of claim 1 further comprising means for purginggas vapors and constituents to be condensed and collected.
 16. Themethod of claim 1 wherein discharge air stream is recirculated belowtrays to form a substantially closed loop system.
 17. The method ofclaim 1 wherein said bottom part is a screen.
 18. The method of claim 1wherein said bottom part is slotted.
 19. The method of claim 1 whereinsaid one or more removable trays has fork lift pockets.
 20. The methodof claim 1 wherein said one or more removable trays has a loadingcapacity of at least about 2.5 cubic yards.
 21. The method of claim 1wherein said vessel further comprises a device for mechanicallyagitating matrices, said means for mechanically agitating beingpositioned in said interior and connected to said vessel.
 22. The methodof claim 1 wherein said manifold comprises a heat resistant gaskettouching said vessel.
 23. The method of claim 1 wherein said manifoldcontains a 1 to 100 micron dry filter.
 24. The method of claim 1 whereinsaid vessel comprises between 1 and 4 of said removable trays.
 25. Themethod of claim 1 wherein said vessel is permanently mounted.
 26. Themethod of claim 1 wherein said manifold is not attached to said vessel.27. The method of claim 1 wherein said vessel is mobile.
 28. The methodof claim 1 wherein said vessel comprises a hydraulic system, saidhydraulic system being positioned under said manifold and being capableof lifting said manifold from said vessel.